Ford Mustang Mach-E Power Loss Problems Results in Recall of 34,762 Vehicles With Extended-Range Batteries

Nearly 35,000 Ford Mustang Mach-E vehicles that were previously recalled due to battery failures are being recalled again, due to defects that may cause unexpected loss of motive power, even after prior recall repairs were completed.

The National Highway Traffic Safety Administration (NHTSA) announced the Ford Mustang Mach-E recall on October 17, after investigating more than one hundred consumer complaints involving vehicles losing power after receiving Ford’s recall remedy.

The vehicles were subject to a recall in June 2022, after it was discovered that the high voltage battery contactors could overheat, causing an immediate loss of vehicle power, increasing the risk of an auto accident.

Ford provided affected vehicle owners with a Secondary On-Board Diagnostic Control Module (SOBDMC) software update, and a Battery Energy Control Module (BECM) software update, to prevent further damage by monitoring the temperature and reducing battery power. The automaker also issued a technical service bulletin to replace the High Voltage Battery Junction Box (HVBJB) to remedy the issue.

However, the NHTSA has received multiple reports of repaired vehicles continuing to lose motive power after receiving the software updates and replacement HVBJB, which prompted an investigation into the recall remedy.

Ford Mustang Mach-E Recall Repair Investigation

Ford initially became aware of the power failure problems and issued a recall in June 2022, affecting approximately 48,924 model year 2021 through 2022 vehicles manufactured from May 27, 2020 until May 24, 2022. The recall followed hundreds of warranty claims involving overheated high voltage battery contactors, which prevented the parts from properly closing or welded them shut.

The NHTSA warned that the battery issues could result in an immediate loss of vehicle power, which could lead to the driver losing control of the vehicle and getting into an accident.

To rectify the issue, Ford provided diagnostic and battery energy control module software updates intended to monitor the contactor’s temperature, identify overheating, and reduce battery power to avoid further contactor damage. The software updates were introduced into the production of new Mustang Mach-E vehicles beginning on May 25, 2022. Months later, the automaker released a technical service bulletin to replace the battery junction box of the recalled vehicles.

Following the recall repairs, federal safety officials launched a Ford Mustang Mach-E recall repair investigation on August 17 to determine whether the repairs were adequate, after the agency received at least 12 reports from owners who continued to experience battery failures and loss of driving power after receiving the software updates and replacement parts.

The investigation involved approximately 64,727 model year 2021 through 2022 Ford Mustang Mach-E vehicles. It included vehicles subject to the recall, as well as vehicles produced with the updated software beginning on May 25, 2022, following the recall.

According to the NHTSA investigation, the vehicle’s high voltage battery main contactors were overheating and deforming due to the direct current (DC) fast charging combined with repeated high acceleration events, which caused the battery to fail and resulted in loss of vehicle power.

Officials determined that while Ford’s recall remedy addressed the loss of motive power in vehicles equipped with standard range batteries, it did not rectify the issue for certain vehicles equipped with extended range batteries, which have a much higher probability of sustaining damage to the battery contactors, as they require more electrical power.

Ford Mustang Mach-E Recall

The new Ford Mustang Mach-E recall impacts approximately 34,762 model year 2021 through 2022 Mustang Mach-E vehicles equipped with extended range batteries that were produced between May 27, 2020 and May 24, 2022.

Standard range battery vehicles were not included in the recall, as the variants requires much less power and have a lesser chance of sustaining damage to the contactor.

While no accidents or injuries have been reported in relation to the recalls, Ford has become aware of at least 107 consumer complaints involving vehicles losing power after the high voltage contactors overheated, of which 100 of the incidents involved a higher powered GT or extended range battery vehicle.

Ford expects to begin notifying owners of the recall by mail beginning on October 30, with instructions on how to receive free replacement of their High Voltage Battery Junction Box (HVBJB) by a licensed dealer.

For more information, owners may contact Ford customer service by phone at 1-866-436-7332 and reference recall number 23S56. They may also contact the NHTSA’s Vehicle Safety Hotline by phone at 1-888-327-4236 (TTY 1-800-424-9153), or visit their website at https://www.nhtsa.gov.